Hyster B010 (S30XL) Forklift Service Repair Manual

LIFT TRUCK WEIGHTS*

UNITkglb

S1.25XL (S25XL)24805466

S1.50XL (S30XL) 26705890 S1.75XL (S35XL) 28506285

H1.25XL (H25XL)25305570

H1.50XL (H30XL)27005950

H1.75XL (H35XL)28956385

*Lift trucks equipped with overhead guard, 3264 mm (128.5 in) mast, 1219 mm (48 in) forks, carriage, load backrest extension, gasoline engine and operator.

ITEM CAPACITIES

ENGINE OIL with Filter

Mazda M4–121G Isuzu C240

COOLING SYSTEM HYDRAULIC TANK TRANSMISSION DIFFERENTIAL

LIFTING

MAST SPEEDS

S/H1.75XL

7.8 litre (8.2 qt) 8.1 litre (8.6 qt)

HYDRAULIC SYSTEM 22.7 litre (6.0 gal)

m/sec

m/sec

5.2 litre (5.5 qt) 5.2 litre (5.5 qt) 9.0 litre (9.5 qt)

26.0 litre (6.9 gal)

8.2 litre (6.8 qt)

FUEL TANK BRAKE FLUID0.2 litre (0.5 pt)

Mazda M4–121G Isuzu C240 43.5 litre (11.5 gal)

QUANTITY ft/min

11 ft/min m/sec

PORT

TRANSMISSION PRESSURES

PORT

kPa (psi) 965 to 1170 (140 to 170) 724 to 860 (105 to 125) 724 to 860 (105 to 125) 724 to 860 (105 to 125) 105 to 175 (15 to 25)

NOTES:

For HYSTER transmissions only.

All pressures are measured at 2000 rpm with oil temperature at 50°C (130°F).

The difference in the Forward and Reverse clutch pressures must not be more than 70 kPa (10 psi).

1. TEST PORT 1 – PRESSURE FROM TRANSMISSION PUMP

2. TEST PORT 2 – PRESSURE TO FORWARD CLUTCH

3. TEST PORT 3 – PRESSURE TO REVERSE CLUTCH

4. TEST PORT 4 – OIL PRESSURE TO TORQUE CONVERTER

5. TEST PORT 5 – OIL PRESSURE FROM OIL COOLER

6. TEST PORT 6 – MODULATOR PRESSURE

*On some T43 transmissions and on T42 transmissions before serial number T42M 3040 (and one unit T42M 3068) test ports 3 and 5 are reversed.

PORT 6 Modulator Pressure PORT 5 Lubrication Pressure PORT 4 Torque Converter PORT 3 Reverse Clutch TRANSMISSION

2 PORT 1 Main Regulator Pressure

PORT 2 Torque Converter

PORT 3 Oil Cooler In

PORT 4 Forward Clutch

PORT 5 Reverse Clutch

kPa (psi) 985 to 1103 (140 to 160) 758 to 896 (110 to 130) 345 to 383 (50 to 70) 655 to 793 (95 to 115) 655 to 793 (95 to 115)

NOTES:

For early (horizontal oil filter) transmissions only.

All pressures are measured at 2000 rpm with oil temperature at 50°C (130°F).

1. TEST PORT 1 – MAIN REGULATOR

2. TEST PORT 2 – TORQUE CONVERTER REGULATOR

3. TEST PORT 3 – OIL COOLER

4. TEST PORT 4 – FORWARD CLUTCH PRESSURE

5. TEST PORT 5 – REVERSE CLUTCH

6. TORQUE CONVERTER REGULATOR

HYDRAULIC SYSTEM

LIFT AND STEERING SYSTEM

PUMP TYPE

Controlled Flow Output to Control Valve @ 2000 rpm and No Load LIFT SYSTEM RELIEF PRESSURE* STEERING SYSTEM RELIEF PRESSURE*

*Oil temperature at 55–65°C (130–150°F).

TIRE PRESSURES

Gear Pump with Flow Control Valve 10.0 ± 1.0 litres/min (2.6 ± 0.26 gal/min) 32.9 litres/min (8.7 gal/min) 15.5 ± 0.35 MPa (2250 ± 50 psi) 11.0 ± 0.40 MPa (1595 ± 58 psi)

TRAVEL SPEEDS

BIAS Ply Tires93 kPa (115 psi)

RADIAL Ply Tires1000 kPa (145 psi)

MODEL

H1.25–1.75XL (H25–35XL) S1.25–1.75XL (S25–35XL)

H1.25–1.75XL (H25–35XL)

ENGINE SPECIFICATIONS

FORWARDREVERSE

17.1 km/h (10.61 mph) 20.9 km/h (13.0 mph)

17.1 km/h (10.6 mph) 20.9 km/h (13.0 mph)

ENGINEISUZU C240

Number Of Cylinders

Firing Order Bore And Stroke

Displacement

Compression Ratio

Compression Pressure

Oil Pressure

Ignition Timing

Idle Speed

Governed Speed (No Load)

Stall Speed *

Thermostat Range

Cooling System

Pressure

Valve Clearance

Intake and Exhaust

Fuel Injector Pressure

Fuel Injection Timing

MAZDA M4–121G

4 1–3–4–2 82 mm x 94 mm (3.23 in x 3.70 in) 1985 cm3 (121.1 in3) 8.0 :1

4 1–3–4–2 86 mm x 102 mm (3.39 in x 4.02 in) 2369 cm3 (144.5 in3)

20.0 :1

1075 kPa (156 psi) @ 200 rpm 13° BTDC @ 625 rpm 600–650 rpm

3040 kPa (441 psi) @ 200 rpm

450 kPa (65 psi) Min. @ 3000 rpm

500–550 rpm

2500–2600 rpm 2000–2100 rpm (Gas) 1950–2050 rpm (LPG) 75–78° C (167–172° F)

103 kPa (15psi)

390 kPa (57 psi) Min. @ 1000 rpm

0.3 mm (0.012 in) Hot0.45 mm (0.018 in) Cold

N/A N/A

*Engines with 30 hours of operation or more

2500–2600 rpm 2100–2200 rpm 75–78° C (167–172° F) 103 kPa (15psi) 11.95 MPa (1706 psi) 14° BDTC Static

33 N/A N/A = Not Applicable

FRAME

TORQUE SPECIFICATIONS

ITEMSPECIFICATION

Counterweight Capscrews

Engine Mount to Frame

ENGINE (ISUZU C240)

Cylinder Head Capscrews

Crankshaft Pulley Capscrew

Connecting Rod Cap Capscrews

Flywheel Capscrews

Main Bearing Capscrews

Camshaft Gear Capscrew

Camshaft Thrust Plate Capscrew Idler Gear Capscrew

ENGINE (MAZDA M4–121G)

Cylinder Head Bolts

Main Bearing Cap

Rod Bearing Cap

Timing Gear Case

Flywheel Rocker Arm Support

Engine Mount to Engine

TRANSMISSION

Drive Plate to Torque Converter

Torque Converter Housing to Engine Differential Housing to Transmission

Torque Converter Housing to Transmission

3/8 in capscrews

7/16 in capscrews

DRIVE AXLE

Back Plate to Axle Mount Capscrews

Axle Mount to Frame Bolts and Nuts

Axle Housing to Differential Housing Wheel Nut Studs Wheel Nuts

Axle Capscrews (S–Series)

Axle Capscrews (H–Series)

STEERING AXLE

Pivot Lock Bolt

Steering Cylinder End Plug Cylinder Mount Capscrews

King Pin Nuts

Wheel Bearing Nut

Wheel Nuts (H–Series)

BRAKES

Back Plate to Axle Mount Capscrews

320 N.m (235 lbf ft) 53 N.m (39 lbf ft)

78 N.m (58 lbf ft) 167 N.m (123 lbf ft) 81 N.m (60 lbf ft) 108 N.m (80 lbf ft) 160 N.m (120 lbf ft) 108 N.m (80 lbf ft) 19 N.m (14 lbf ft) 26 N.m (19 lbf ft)

88 N.m (65 lbf ft)

81 to 88 N.m (60 to 65 lbf ft)

47 to 52 N.m (35 to 38 lbf ft)

16 to 23 N.m (12 to 17 lbf ft)

58 to 64 N.m (43 to 47 lbf ft) 28 to 41 N.m (21 to 30 lbf ft) 56 N.m (41 lbf ft)

45 N.m (33 lbf ft) 38 N.m (28 lbf ft) 38 N.m (28 lbf ft)

37 to 43 N.m (27 to 32 lbf ft)

57 to 68 N.m (42 to 50 lbf ft)

122N.m (90 lbf ft)

325 to 380 N.m (240 to 280 lbf ft 65 N.m (49 lbf ft) 155 N m (115 lbf ft) 155 N.m (115 lbf ft) 155 N.m (115 lbf ft) 20 N.m (15 lbf ft)

66 N.m (50 lbf ft)

407 to 475 N.m (300 to 350 lbf ft 130 N.m (96 lbf ft) 90 N m (66 lbf ft) Initial 34 N.m (25 lbf ft) Final 200 N.m (150 lbf ft) Initial 34 N.m (25 lbf ft) Final 237 to 305 N.m (175 to 225 lbf ft)

122 N.m (90 lbf ft)

TORQUE SPECIFICATIONS

ITEMSPECIFICATION

HYDRAULIC PUMP

Adjustment Screw Acorn Nut Plug for Relief Valve Plug for Regulator Valve Capscrews for Body

HYDRAULIC CONTROL VALVE

28 to 31 N.m (20 to 23 lbf ft) 34 to 39 N.m (25 to 29 lbf ft 59 to 69 N m (43 to 51 lbf ft) 46 to 49 N.m (34 to 36 lbf ft)

Through Bolts 5/16 in 3/8 in 19 N.m (14 lbf ft) 45 N.m (33 lbf ft)

TILT CYLINDERS

Rod End capscrews 42 N.m (31 lbf ft)

MAST

Mast Hanger to Mast Capscrews Mast Hanger Cap Capscrews 555 N.m (410 lbf ft) 66 N.m (50 lbf ft)

INTRODUCTION

GENERAL

This section has the description and repair procedures for the steering axle. See the following sections for additional information on the steering system.

THE STEERING CONTROL UNIT, 1600 SRM 54

THE STEERING CONTROL UNIT, 1600 SRM 257

THE HYDRAULIC SYSTEM AND GEAR PUMP ASSEMBLY, 1900 SRM 130

DESCRIPTION (See FIGURE 1.)

The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. The steering axle is articulated and is connected to the frame by a center pivot pin. The pivot pin permits the steering axle to rotate at the frame mount when the lift truck travels over rough surfaces.

The ends of the piston rod extend from both ends of the steering cylinder shell. A single piston and the seal are in the center of the rod. Oil pressure on one side of the piston moves the piston in the bore. The piston pushes an equal amount of oil from the opposite side of the cylinder.

A relief valve in the hydraulic pump controls the oil pressure when the piston reaches the end of the stroke. The tie rods that connect the spindle arms to the cylinder are not adjustable.

Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a king pin. The preload on the bearings is controlled by a nut on the bottom of the king pin.

The wheel hubs rotate on two tapered roller bearings and are held on the spindles by a castle nut. The bearing preload of the wheel hubs is adjusted by the castle nut. The grease seals protect the bearings from dirt and water. Wear sleeves protect the hub from wear by the seals.

REPAIRS

WARNING

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: upright, drive axle, engine and transmission, and the counterweight. when the lift truck is put on blocks, put additional blocks in the following positions:

a.Before removing the upright and drive axle, put blocks under the counterweight so that the lift truck can not fall backward.

b.Before removing the counterweight, put blocks under the upright assembly so that the lift truck can not fall forward.

Put the lift truck on blocks only if the surface is solid, even, and level. Make sure that any blocks used to support the lift truck are solid, one piece units.

Make sure the lift truck is in a position of stability before making repairs. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.

NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the lift truck so that blocks can be installed.

The following examples are given to help you make an estimate of the weight that will be lifted.

1. The approximate weight of a lift truck on the steering axle:

S1.25XL (S25XL)1315 kg (2900 lb)

S1.50XL (S30XL) 1555 kg (3430 lb)

S1.75XL (S35XL)1790 kg (3950 lb)

H1.25XL (H25XL)1365 kg (3010 lb)

H1.50XL (H30XL)1575 kg (3470 lb)

H1.75XL (H35XL)1825 kg (4025 lb)

H2.00XL (H40XL)1700 kg (3800 lb)

H2.50XL (H50XL)2080 kg (4600 lb)

H3.00XL (H60XL)2555 kg (5630 lb)

H2.00J (H40J)1860 kg (4100 lb)

H2.50J (H50J)2150 kg (4740 lb)

H3.00JS (H60JS)2700 kg (6000 lb)

2. The weight of a steering axle without wheels is approximately 95 kg (210 lb).

NOTE: The wheels, hubs, bearings, spindles, cylinder, and tie rods can be removed with the axle in the lift truck.

STEERING AXLE

Removal (See FIGURE 2.)

Put the back of the lift truck on blocks. Remove the counterweight. Disconnect the hydraulic lines and install caps on the cylinder fittings and the open hydraulic lines. The caps will prevent the spindle from turning as the axle is removed from under the lift truck. Put a lifting device under the axle. Remove the bolt that holds the pivot pin in the frame mount. Remove the pivot pin from the frame mount. The end of the pivot pin has an M12 x 1.75 threaded hole. Install a threaded puller in the pivot pin. Pull the pivot pin out of the frame. Use the access hole in the counterweight if equipped. Lower the axle from the frame and move the axle from the lift truck.

Installation

Check that the pivot pin bushings are in good condition. If the bushings are worn or damaged, replace them. Use a floor jack or another lift truck to lift the steering axle into the correct position. Align the axle with the frame mount. Apply grease to the pivot pin for easier installation. Install the pivot pin and the bolt that holds the pivot pin in the frame mount. Tighten the bolt to 66 N.m (50 lbf ft). Connect the hydraulic lines. Install the counterweight. Remove the air from the system by turning the steering wheel several times from stop to stop when the engine is running.

STEERING CYLINDER

Removal (See FIGURE 2.)

Disconnect the hydraulic lines at the steering cylinder. Rotate the ends of the hydraulic lines away from the steering cylinder. Disconnect the tie rods at the ends of the cylinder rod. Remove the capscrews that fasten the steering cylinder to the axle. Remove the steering cylinder from the axle. Make a note of any shim arrangement under the steering cylinder mounts.

1.STEERING CYLINDER

2.MOUNT BOLTS

STEERING CYLINDER

3.FRAME, STEERING AXLE

4.TIGHTEN TO 130 Nm (96 lb ft)

5.TIGHTEN TO 225 Nm (166 lb ft)

6.TIGHTEN TO 165 Nm (120 lb ft)

1.ROD

2.CYLINDER SHELL

3.END CAP

4.BACK–UP RING

5.O–RING

EARLY MODELS

LATE MODELS

6.WIPER RING

7.ROD SEAL

8.PISTON

9.PISTON SEAL

10.SQUARE RING

Service (See FIGURE 4.)

FIGURE 4. STEERING CYLINDER

On early cylinders, use a spanner to remove the end caps. On later models, pull the end caps from the cylinder shell. Repair the cylinder as necessary. Use new seals and O–rings. Make sure the arrangement of the seals and O–rings is correct. (See FIGURE 4.) On early models, tighten the end caps to 407 to 475 N.m (300 to 350 lbf ft).

Installation (See FIGURE 4.)

Install the steering cylinder on the axle. On early units, install the shims under the bottom steering cylinder mount from which they were removed. Tighten the capscrews as shown in FIGURE 4. Connect the tie rods

to the end of the cylinder rod. Connect the hydraulic lines. Remove air from the hydraulic system. Turn the steering wheel several times from stop to stop when the engine is running.

HUBS (See FIGURE 5.)

Removal

Remove the wheels to service the hubs (except for the “S” series lift trucks). Remove the grease cap in the hub for access to the bearings. Remove the nut, the outer bearing assembly, and the hub. Check for damage or wear on the bearings. If the bearings or the seals are to be replaced, use a brass driver to remove the inner bearing assembly from the hub.

1

1.GREASE CUP 2.CASTLE NUT

3.OUTER BEARING 4.HUB 5.INNER BEARING 6.WEAR SLEEVE

Installation

7.SEAL 8.SPINDLE 9.PIN 10.KING PIN 11.O–RING 12.SPINDLE SEAL

13.BEARING 14.BEARING CUP 15.SEAL 16.SPACER 17.CASTLE NUT 18.COTTER PIN

19.FRAME 20.TIE ROD 21.BUSHING 22.TIE ROD PIN 23.BELLEVILLE WASHER 24.STUD

Lubricate the two hub bearings with multi–purpose grease. Install the seal and the inner bearing in the hub. Install the hub on the spindle. Install the outer bearing, washer and nut. Tighten the nut to 200 N.m (150 lbf ft) while rotating the hub. Loosen the nut until the hub rotates freely. Tighten the nut to 34 N.m (25 lbf ft). Lock the nut in position with a cotter pin at the first alignment slot that occurs at approximately 34 N.m (25 lbf ft)

NOTE: On H1.25–1.75XL (H25–35 XL) units, install the studs with Loctite and tighten to 30 to 50 N.m (22 to 37 lbf ft).

5. SPINDLE AND HUB ASSEMBLY

SPINDLES (See FIGURE 5.)

Removal

5 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 16 9777 Remove the wheels from the steering axle to service the spindles. Remove the hubs. Disconnect the tie rods from the spindle. Remove the cotter pin and nut from the bottom of the king pin. Use a driver to remove the king pin. Remove the sleeve and then the spindle from the axle. Use a driver to remove the bearings and seals from the spindle.

FIGURE NOTE: Dirt and corrosion can make the spacer difficult to remove from the steering axle frame. A machined space is put in the top of the spacer so that the spacer can be removed with a bearing puller.